PROJECT-SPECIFIC DEP SPECIFICATION

DEFINITION OF TEMPERATURE, PRESSURE AND

TOXICITY LEVELS

DEP 01.00.01.30-SCAPSA PQ2022

February 2017

ECCN EAR99

DESIGN AND ENGINEERING PRACTICE

DEM1

© 2017 Shell Group of companies

All rights reserved. No part of this document may be reproduced, stored in a retrieval system, published or transmitted, in any form or by any means, without the prior
written permission of the copyright owner or Shell Global Solutions International BV.

This document contains information that is classified as EAR99 and, as a consequence, can neither be exported nor re-exported to any country which is under an
embargo of the U.S. government pursuant to Part 746 of the Export Administration Regulations (15 C.F.R. Part 746) nor can be made available to any national of such
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Administration Regulations (15 C.F.R. Part 744).
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PREFACE

DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global Solutions
International B.V. (Shell GSI) and, in some cases, of other Shell Companies.
These views are based on the experience acquired during involvement with the design, construction, operation and
maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference international,
regional, national and industry standards.
The objective is to set the standard for good design and engineering practice to be applied by Shell companies in oil and
gas production, oil refining, gas handling, gasification, chemical processing, or any other such facility, and thereby to help
achieve maximum technical and economic benefit from standardization.
The information set forth in these publications is provided to Shell companies for their consideration and decision to
implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each
locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the
information set forth in DEPs to their own environment and requirements.
When Contractors or Manufacturers/Suppliers use DEPs, they shall be solely responsible for such use, including the
quality of their work and the attainment of the required design and engineering standards. In particular, for those
requirements not specifically covered, the Principal will typically expect them to follow those design and engineering
practices that will achieve at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or
Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal.
The right to obtain and to use DEPs is restricted, and is typically granted by Shell GSI (and in some cases by other Shell
Companies) under a Service Agreement or a License Agreement. This right is granted primarily to Shell companies and
other companies receiving technical advice and services from Shell GSI or another Shell Company. Consequently, three
categories of users of DEPs can be distinguished:
1) Operating Units having a Service Agreement with Shell GSI or another Shell Company. The use of DEPs by these
Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement.
2) Other parties who are authorised to use DEPs subject to appropriate contractual arrangements (whether as part of
a Service Agreement or otherwise).
3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2)
which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said
users comply with the relevant standards.
Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI disclaims
any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person
whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs
or any part thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell Company. The
benefit of this disclaimer shall inure in all respects to Shell GSI and/or any Shell Company, or companies affiliated to these
companies, that may issue DEPs or advise or require the use of DEPs.
Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall
not, without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and the
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copyright of DEPs vests in Shell Group of companies. Users shall arrange for DEPs to be held in safe custody and Shell
GSI may at any time require information satisfactory to them in order to ascertain how users implement this requirement.
All administrative queries should be directed to the DEP Administrator in Shell GSI.
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TABLE OF CONTENTS
PART I INTRODUCTION ........................................................................................................ 4
1.1 SCOPE ....................................................................................................................... 4
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS ......... 4
1.3 DEFINITIONS ............................................................................................................. 4
1.4 CROSS-REFERENCES ............................................................................................. 7
PART II DEFINITION OF PRESSURE AND TEMPERATURE ............................................... 8
1 PRESSURE SYSTEM ................................................................................................ 8
2 TEMPERATURE AND PRESSURE LEVELS ............................................................ 8
2.1 TEMPERATURE ......................................................................................................... 8
2.2 PRESSURE .............................................................................................................. 13
PART III DEFINITION OF TOXICITY ...................................................................................... 21
1 TECHNICAL ASSURANCE ..................................................................................... 21
2 BACKGROUND ........................................................................................................ 21
3 TOXICITY CLASSIFICATION OF SUBSTANCES .................................................. 21
3.1 GENERAL ................................................................................................................. 21
3.2 TOXICITY CLASSIFICATION OF SUBSTANCES UNDER THE GLOBALLY
HARMONISED SYSTEM OF CLASSIFICATION AND LABELLING (GHS) ............ 23
3.3 APPLICATION TO PETROLEUM SUBSTANCES ................................................... 24
4 SPECIFIED ENGINEERING CONTROLS BASED ON THE SHELL TOXICITY
DEFINITION .............................................................................................................. 24
5 SELECTION OF SHELL TOXICITY DEFINITION UNDER GHS ............................ 24
5.1 GENERAL ................................................................................................................. 24
5.2 EXPLANATION OF THE PROCESS STEPS ACCORDING TO GHS ..................... 26
PART IV REFERENCES ......................................................................................................... 29
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PART I INTRODUCTION

1.1 SCOPE
This DEP specifies requirements and gives recommendations for determining temperatures
and pressures in design and operation (Part II). It also defines substances with regard to
their toxicity, for which other DEPs may specify additional design and engineering
requirements (Part III).
The custodianship and accountability for this DEP resides with the Process Engineering
discipline. However, the definition of toxicity is a technical competency that is maintained in
the Health discipline in Shell. As such, the relevant subject matter experts and the
custodianship for (Part III) of this DEP are with the Health discipline.
This DEP contains mandatory requirements to mitigate process safety risks in accordance
with Design Engineering Manual (DEM) 1 – Application of Technical Standards.

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorised by Shell GSI, the distribution of this DEP is confined to Shell
companies and, where necessary, to Contractors and Manufacturers/Suppliers nominated
by them. Any authorised access to DEPs does not for that reason constitute an
authorisation to any documents, data or information to which the DEPs may refer.
This DEP is intended for use in facilities related to oil and gas production, gas handling, oil
refining, chemical processing, gasification, distribution and supply/marketing. This DEP
may also be applied in other similar facilities.
When DEPs are applied, a Management of Change (MOC) process shall be implemented;
If national and/or local regulations exist in which some of the requirements could be more
stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the
requirements are the more stringent and which combination of requirements will be
acceptable with regards to the safety, environmental, economic and legal aspects. In all
cases, the Contractor shall inform the Principal of any deviation from the requirements of
this DEP which is considered to be necessary in order to comply with national and/or local
regulations. The Principal may then negotiate with the Authorities concerned, the objective
being to obtain agreement to follow this DEP as closely as possible.

1.3 DEFINITIONS
1.3.1 General definitions
The Contractor is the party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a
facility. The Principal may undertake all or part of the duties of the Contractor.
The Manufacturer/Supplier is the party that manufactures or supplies equipment and
services to perform the duties specified by the Contractor.
The Principal is the party that initiates the project and ultimately pays for it. The Principal
may also include an agent or consultant authorised to act for, and on behalf of, the
Principal.
The word shall indicates a requirement.
The capitalised term SHALL [PS] indicates a process safety requirement.
The word should indicates a recommendation.
The word may indicates a permitted option.
1.3.2 Specific definitions

Term Definition
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Term Definition

Critical The lowest process or atmospheric temperature at which equipment

Exposure metal will be exposed to a given stress. The CET may be a single
Temperature temperature at an operating pressure, or an envelope of temperatures
(CET) and pressures/stresses. CET is equivalent to the MMT when exposure
temperature is not referenced to coincident pressures or stresses.

Intended Operation in which process conditions, i.e., temperature, pressure, flow,

operation fluid compositions, etc., are stable and in accordance with the process
design.

Incidental Infrequent transient conditions for short durations associated with

operation pipeline operation as the result of surge, failure of a control valve,
accumulation of pressure during activation of an overpressure
protection device.

Minimum The lowest metal temperature allowed for a given material, at a

Allowable specified thickness, based on its brittle fracture resistance. MAT can be
Temperature a single temperature, in which case it is the same as the LDT when
(MAT) associated with the design pressure. It can alternatively be an envelope
of allowable temperatures as a function of pressure or stress.

MSDS Materials Safety Data Sheet

Pressure Generic term for relief valves, safety valves or safety/relief valves.
relief valve

Pressure Generic term for pressure relief valves, pressure rupture disks, or other
relief device mechanical emergency relief appliances.

ppm-volume Molar concentration of a substance in parts per million.

Very toxic Substances that are very hazardous for the environment or human
(substances) health.
NOTES: 1. "Toxic" substances are classified as such in databases
such as the European Chemical Substances
Information System (ESIS) and the Globally
Harmonised System of Classification and Labelling
(GHS).
2. This DEP further classifies very toxic substances as
"very toxic - acute", "very toxic - chronic" and "very toxic
- environment".
3. Where a substance has been deemed “very toxic
acute” on the basis of the definitions in (4) of this
document, there may be over conservativeness in
specifying equipment if the classification has been
reached as a result of R34, R35 (causes (severe)
burns) or H314/H318 (causes severe skin burns and
eye damage).

1.3.3 Abbreviations

Term Definition

ABP Atmospheric Boiling Point

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Term Definition

AFT Adiabatic Flash Temperature

CAS Chemical Abstracts Service

CLP Classification, Labelling and Packaging

CMR Carcinogen, Mutagen, Reprotoxicant

DP Design Pressure

DSD Dangerous Substances Directive

DT Design Temperature

EDT Emergency Design Temperature

GHS Globally harmonized system of classification and labelling

HPd Hydrostatic Pressure of the liquid above the pump discharge)

HPo Pump differential pressure at no flow, maximum pump speed and

highest density as per process design (pump shutoff differential
pressure)

HPs Hydrostatic Pressure of the liquid above the pump suction

LAT Lowest Ambient Temperature

LDP Lower Design Pressure

LDT Lower Design Temperature

MAIP Maximum Allowable Incidental Pressure

MAOP Maximum Allowable Operating Pressure

MAT Minimum Allowable Temperature

MAWP Maximum Allowable Working Pressure

MDMT Minimum Design Metal Temperature

MMT Minimum Metal Temperature

MOP Maximum Operating Pressure

MOT Maximum Operating Temperature

OP Operating Pressure

SOP Shut-off Pressure

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1.4 CROSS-REFERENCES
Where cross-references to other parts of this DEP are made, the referenced section or
clause number is shown in brackets ( ). Other documents referenced by this DEP are listed
in (Part IV).
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PART II DEFINITION OF PRESSURE AND TEMPERATURE

1 PRESSURE SYSTEM
A pressure system is an individual equipment item or a group of equipment including
associated piping that within its boundaries remains open under all conditions, and it can
be demonstrated that blockage due to freezing, solidification, fouling, sublimation,
damage of internals, scale, debris, foreign objects, etc., cannot occur.
6. If block (stop) valves are included in the system, the requirements of ASME VIII
Division 1 Appendix M-5 shall be met.
7. The system design pressure SHALL [PS] not be higher than the pressure rating of any
system component.
8. The effects of static head shall be taken into account.
9. When a system approach is taken, the hydraulics shall be evaluated to ensure that no
equipment exceeds its design pressure before a pressure relief device activates, and
during relieving conditions, no equipment exceeds the allowable accumulation
permitted by either the applicable code or local requirements.

2 TEMPERATURE AND PRESSURE LEVELS

2.1 TEMPERATURE
2.1.1 Operating temperature
The operating temperature is the temperature that prevails inside equipment and piping
during the predominant intended operation.
1. The process engineer shall determine the operating temperature.
2. Where vessel operation can be switched from a high pressure moderate temperature
operation to a lower pressure but higher temperature one (e.g., regeneration), then the
option of designing for those separate operating modes may be considered (e.g., dual
pressure/temperature ratings for the equipment).
2.1.2 Maximum operating temperature (MOT)
1. The MOT shall be established for operational flexibility and required control system
variations.
2. The MOT shall be greater than or equal to the operating temperature.
3. The maximum operating temperature SHALL [PS] cover intended operations.
This includes: start up, shut down, drying, regeneration, steam-air decoking,
heating up to maximum ambient temperature, including solar radiation, fouling of
heat exchangers, heat exchanger by-passing.
4. The MOT shall be determined by the process engineer in consultation with the
process control engineer.
5. The MOT is normally used as the basis for materials selection with respect to long
term corrosion and/or material degradation. Therefore, any subsequent proposed
change in MOT shall be reviewed to confirm the continued suitability of the material.
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2.1.3 Upset temperature

The upset temperature is the maximum temperature that can be reached under
unintended, but possible, upset conditions assuming no barriers are in place.
Typical upset scenarios include excessive process heat input (e.g., due to control failure,
valve mis-operation, etc.) and loss of cooling medium to the system (e.g., due to power
failure, valve closure, pump failure).
1. The potential for upset temperatures exceeding the MOT due to exotherms,
decompositions, or runaway reactions SHALL [PS] be mitigated by one of the
following:
a. increased design temperature;
b. instrument safeguards;
c. other barriers as determined from a risk assessment.
2. Refer to DEP 01.00.02.12-Gen for methods to document the mitigation methods.
3. Potential high wall temperatures resulting from non-fire case pressure relief,
depressuring, mis-operation, or other upsets shall be mitigated by increased design
temperature.
a. Where this temperature is considerably higher than the MOT (for example, such
that there would be a significant impact on mechanical design, material selection
and cost), then use of instrument safeguards and other barriers as determined
during risk assessment may be considered in lieu of increased design
temperature.
4. The temperature shall be determined using the coincident pressure and fluid
composition for the upset scenario.
5. Fire exposure is an emergency condition that can result in wall temperatures higher
than the equipment MOT. Since all equipment exposed to fire will be subject to
inspection, repair or replacement, consideration of the fire exposure scenario for
establishing the design temperature shall be as follows:
a. do not use fire case temperatures for establishing design temperature;
b. if required by Principal (typically in support of Hazard and Effects Management
Process (HEMP) activities), carry out an assessment of the risk and required
mitigations of the impact of fire exposure.
6. Upset conditions should be assumed to prevail only for the time required to correct the
situation.
7. These conditions shall be taken into account both in materials selection (for corrosion
and/or material degradation) and mechanical design, recognising that these conditions
prevail for a limited period of time and not indefinitely.
8. The duration of the emergency and the materials selection limitations shall be agreed
with the Principal.
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2.1.4 Design temperature

The design temperature is used for the mechanical design (e.g., determination of
minimum wall thickness and other physical characteristics) of equipment and piping.
The design temperature is often referred to as the upper design temperature. This is the
highest temperature to which equipment is designed at the design pressure.
The design temperature is initially selected by the process engineer and finally
determined in close consultation with the mechanical design engineer.
2. The design temperature SHALL [PS] be equal to or greater than the MOT.
The design temperature is typically at least 10 °C (18 °F) above the MOT.
3. The process engineer shall incorporate the evaluation of upset temperatures as per
(Part II, 2.1.3, Item 1) in establishing the design temperature.
4. The design temperature shall be rounded up to nearest 5 °C (10 °F) increment.
5. In exceptional cases (e.g., where a higher alloy material would otherwise be required
because of oxidation or creep), a discussion is required between the process engineer
and the related mechanical discipline engineers to decide on an acceptable
implementation. In such cases, the rationale for the decision taken shall be
documented and approved by the Principal.
6. For unfired heat exchangers the design temperature of the cold side should be set
equal to the hot side to simplify safeguarding.
a. Alternative design temperature for the cold side may be applied subject to review
and approval by the Principal.
7. For tubes in fired equipment, the design temperature shall be either the temperature
determined by the rules specified in (2.1.4, Item 1) through (2.1.4, Item 4) or the
calculated maximum tube skin temperature, whichever is higher.
8. For electrical process heaters, the design temperature of the shell shall be selected in
accordance with the over-temperature protection trip settings of the electrical heating
elements.
9. For equipment in acidic and caustic services (i.e., HCl, H2SO4, NaOH, KOH), attention
should be paid to the material selected versus the strength of solution being used to
avoid unnecessary cost when applying margins above MOT to derive Design
Temperature.
10. For systems where steam out is intended, the steam out pressure/temperature
combination should be specified as a separate design case.
Typical steam-out conditions are a temperature of 150 °C (300 °F) under full
vacuum.
11. For systems where a design temperature has been specified at a value less than
120 °C (250 °F), the Contractor may elect to designate the design temperature as
120 °C (250 °F) since often there is no increase in flange rating requirement.
This might offer flexibility for steam out equipment or utilities.
12. Refer to DEP 01.00.02.12-SCAPSA PQ2022. for basis for documenting the design
temperature.
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2.1.5 Minimum metal temperature (MMT)

4. The MMT is the lowest metal temperature that equipment could possibly reach and
shall be defined for all equipment, pipelines and piping systems.
5. The MMT SHALL [PS] be specified based upon the minimum of the following:
a. the lowest normal operating temperature;
b. the lowest temperature during start-up (including initial filling of an empty system)
or shutdown;
c. lowest ambient temperature (LAT);
d. the temperature during exceptional cool down events caused by high rate
depressurisation, resulting in either Joule-Thomson cooling of low molecular
weight gases, or auto-refrigeration of liquefied light hydrocarbons or other
process upset conditions;
The potential for high rate depressurisation is normally evaluated when
determining the MMT for equipment and piping containing compressed low
molecular weight hydrocarbon fluids such as methane, ethane, propane,
propylene, or ethylene, and compressed CO2 or N2.
In the case of boiling of liquefied gas, the MMT is usually the adiabatic flash
temperature (AFT) or the atmospheric boiling point (ABP) unless vacuum
conditions can cause boiling below these temperatures.
Normal assessment of the MMT during depressurising only considers the
process fluids adiabatically, but the heat contained in the process equipment
itself may be included in decisive cases, if documented quantitatively.
Typical upset scenarios include excessive cooling (e.g., due to control failure,
valve mis-operation) and loss of heating medium to the system (e.g., due to
power failure, valve closure, pump failure).
6. The MMT for equipment containing multiple fluids (e.g., columns or shell & tube heat
exchangers) shall take into account the temperature, pressure and mass flow rates of
each fluid during all possible cool down scenarios:
a. each piece of equipment shall have a single MMT equal to the lowest possible
temperature of any of the fluids;
b. different MMTs for parts of the same equipment (e.g., top and bottom of columns
or tube-side and shell-side of heat exchangers) should be selected only when
justified by an economic analysis and approved by the MMI Technical Authority of
the Principal.
Additional guidance for evaluating the MMT for specific equipment types is provided
in DEP 30.10.02.31-Gen (5).
2.1.6 Lower design temperature (LDT)
1. The Lower Design Temperature (LDT) is the lowest temperature at which equipment
may be subjected to its design pressure.
This parameter marks the lowest temperature at which equipment is protected from
overpressure by a safety relief system.
2. When defined for a pressure equal to the design pressure, the following shall be
equivalent to the LDT:
a. the Minimum Design Metal Temperature in ASME Section VIII, Div. 1, clause UG-
20 and ASME Section VIII, Div. 2, clause 4.1.5.2;
b. the Design Reference Temperature in PD 5500 Annex D;
c. the Design Reference Temperature in EN 13445-2 Clause 3.1.3.
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3. To prevent brittle fracture, the selected LDT SHALL [PS] be based on one of the
following criteria, in order of preference:
a. Option 1. The LDT is equal to or colder than the MMT;
b. Option 2. The LDT is equal to or colder than the MMT but the LDT is determined
on the basis of reduced design stress, relative to the maximum code allowable
stress, in accordance with the rules in the applicable design code:
i. the maximum temperature credit allowed is 50 °C (90 °F);
ii. temperature credits greater than 50 °C (90 °F) are justified on the basis of a
fracture mechanics analysis using internationally recognised standards, and
approved by the MMI Technical Authority of the Principal.
c. Option 3. The LDT may be warmer than the MMT, but only when the General
2
Membrane Stress is less than 50 N/mm (7250 psi) for the operating scenarios
where the fluid temperature is colder than the LDT;
Selecting this option would need to be justified by significant cost savings to
balance the cost of process control, instrumented safeguarding and production
2
restraints required to prevent operation at a stress level above 50 N/mm
(7250 psi).
d. Option 4. When the controlling MMT is associated with a depressuring scenario,
the selected materials may also be qualified on the basis of a comparison of the
MAT and CET curves.
Option 4 is only selected if justified by significant cost savings, including the
cost of process control and production restraints required to prevent operation
on the unsafe side of the MAT curve.
4. Where the selected LDT is based on Option 2, Option 3 or Option 4 in (2.1.6, Item 3),
the following requirements SHALL [PS] also apply:
a. identify scenarios that could lead to re-pressurisation, or pressurisation from
connected systems, whilst the equipment is colder than the LDT;
b. assess the Risk of each scenario and define the Risk mitigation in accordance
with the Managing Risk manual of the HSSE & SP Control Framework;
c. the resulting documented ALARP statements for these scenarios shall be
approved by the designated Technical Safety Technical Authority of the Principal.
5. For equipment or piping systems where the LDT is governed by LAT, the effect of heat
tracing, insulation, winterization, or implementation of procedures that require heat-up
prior to pressurization shall be evaluated in line with (2.1.6, Item 4).
In some cases, credit can be taken for one or more of these items, which will allow
the selected LDT to be warmer than LAT.
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2.2 PRESSURE
2.2.1 Pressures in process design and in mechanical pressure system design
2.2.1.1 Operating pressure (OP)
The OP is the gauge pressure which prevails inside equipment and piping during any
intended operation.
1. The OP shall be determined by the process engineer.
2.2.1.2 Maximum operating pressure (MOP)
The MOP is typically at least 105% of the OP in order to provide sufficient flexibility for
the control of the intended operations.
1. The MOP shall be determined by the process engineer in consultation with the
process control engineer.
2. The MOP shall be not less than 1.0 bar (15 psi) above the OP, except in pressurised
LPG storage facilities, where the MOP is equal to the vapour pressure at the derived
maximum operating temperature (see (Part II, 2.1.2)) and assessed LPG composition:
a. if this margin is not sufficient for control, starting up, shutting down or other
specific operations, a higher MOP shall be specified and the reason for this
increased MOP stated in the pertaining documents.
For applications where slugging and surging is a concern (e.g., from deepwater
subsea wells), substantial margins above ‘steady state’ operating pressure could be
required.
3. For pipeline application Maximum Allowable Operating Pressure (MAOP) or MOP is
the maximum internal pressure at which a pipeline system or parts thereof is allowed
to be operated. MAOP should not exceed 80% of the hydrotest pressure.
4. Start-up conditions where gathering system flow lines and pipelines have ‘packed’
shall be evaluated.
2.2.1.3 Design pressure (DP)
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2.2.1.3.1 General
The Design Pressure (DP) is the highest gauge pressure that, according to mechanical
design codes, a system or piece of equipment can be continually subjected to at or
below the Upper Design Temperature, and above the Lower Design Temperature. This
pressure typically provides the basis for relief valve set pressures, and actual operating
conditions (OP, MOP) are below this pressure.
The DP is initially selected by the process engineer and finally determined in close
consultation with the mechanical design engineer.
1. The maximum difference in pressure between the inside and outside of the equipment,
or between any two chambers in a combination unit, shall be considered.
2. The DP shall be rounded up to the next 0.5 barg (10 psig) increment.
3. For an individual piece of equipment the Design Pressure is defined at the highest part
of the equipment. The equipment designer shall account for static head in determining
mechanical requirements for the lower parts of the equipment.
4. For systems comprising multiple connected pieces of equipment, the Design Pressure
of the individual equipment shall be established accounting for maximum static head
imposed by fluids as well as frictional pressure drop in non-flowing and flowing
condition.
a. Refer to API STD 521 Appendix B-1 for methodology and criteria for systems with
multiple equipment protected by a single Pressure Relief Device.
5. For atmospheric vessels/equipment, the design pressure should be specified in order
to provide a basis for safeguarding.
Example - Atmospheric equipment connected to or controlled by a control/relief
valve such as gas blanket of a tank.
6. Equipment and piping at the discharge side of positive displacement compressors and
pumps shall have sufficiently high design pressures to prevent the opening of pressure
relief devices due to pressure fluctuations
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2.2.1.3.2 Vapour and vapour-liquid systems protected by relief valves

For non-liquid full systems with a vapour relief to a common flare or vent system the DP
is normally determined from the MOP by the guidance in Table 1 :
Table 1 Determination of DP based on MOP

3. Equipment that is part of a pressure system protected by a relief valve discharging into
a flare system or combined vent system SHALL [PS] have a minimum design pressure
of at least 3.5 barg (50 psig) due to the potential backpressure exerted on the relief
device. This requirement does not apply to systems comprising tanks and other
atmospheric systems with dedicated vapour collection systems and flare systems.
When using sonic flare tips, the minimum design pressure might need to be
considerably higher than 3.5 barg (50 psig).
4. Design pressures lower than 3.5 barg (50 psig) may be considered if the relief valve
discharges directly to atmosphere or is routed to a downstream system that has a
design pressure of less than 3.5 barg (50 psig).
5. The Contractor shall validate that the selected design pressure is sufficiently high to
allow pressure relief into the flare header at maximum calculated back pressure.
For flare KO Drums, refer to DEP 80.45.10.10-SCAPSA PQ2022. (Part IV, 5.7.9) for
additional requirements.
6. If a DP of 110% MOP is substantially more costly than a DP of 105% MOP (e.g.,
because of a step up in flange rating), then 105% MOP may be applied, subject to the
approval of the Principal, and subject to use of relief valves that can have their set
pressure adjusted to the required accuracy.
For example, pilot operated relief valves.
7. The DP shall be greater than MOP by sufficient margin to allow operation of any
instrumented high pressure alarms and trip functions that are set at or above MOP
and are intended to prevent over-pressurisation, or to avoid relief valves lifting.
This could require a bigger margin than the minimum in Table 1.
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8. It should be evaluated whether the application of design pressures that are higher than
those that follow from (2.2.1.3.2, items 1 to 5) could result in an overall cost saving.
This is likely when the equipment's minimum wall thickness is determined not by
internal pressure, but by external pressure or external loads, e.g., wind load or
protection against deformation during transport and installation.
9. For systems in which a batch reaction takes place and a relief valve is not sized for
any potential thermal runaway, these cases shall be:
a. subject to the approval of the Principal;
b. in accordance with the requirements specified in ASME VIII, Div 1, UG-140.
For batch reactions, it is sometimes possible (when not prohibitively expensive) to
select a sufficiently high design pressure so that in the event of a runaway, the
system’s pressure still does not exceed the allowable pressure limits (e.g., reactors
and associated piping). In these special cases, the runaway relief case is not
included as a basis for sizing the relief system.
10. For pumps and compressors with an isolation valve between it and upstream system
(e.g., scrubber), the suction lines from and including the suction valve shall have the
same design pressure as on the discharge side.
11. The DP of compressor suction and intermediate stage systems, e.g., coolers,
condensers, knock-out drums, shall be sufficiently high to prevent the opening of
pressure relief valves through pressure equalization “settle out” after the compressor
has shut down.
12. The design pressures for multi-compartment equipment need not take account of
structural failure of separation walls. For heat exchangers refer to
DEP 80.45.10.11-SCAPSA PQ2022. (4.2) for requirements. See also (Part II,
2.2.1.3.5).
13. The design pressures of equipment handling explosive dusts and means of preventing
and mitigating dust explosions shall be subject to the approval of the Principal.
14. Design pressure and temperature should be optimised to eliminate and reduce relief
cases where practically possible, in order to provide an inherently safe and
sustainable unit design and to reduce costs.
Where permitted by local requirements, for the acceptance of occasional variations
of pressure and/or temperature above the design levels in piping systems,
reference is made to ASME B31.1, ASME B31.3, ASME B31.4 and ASME B31.8 as
applicable to the system under consideration.
Example: Higher design pressures could exclude certain large relief cases,
therefore reducing RV sizes, piping and potentially flare capacity.
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2.2.1.3.3 Vapour and vapour-liquid systems protected by pressure rupture disks

1. Rupture disks are highly stressed in service. In order to avoid premature failure due to
the effects of corrosion, creep and fatigue, a substantial margin (at least 30 % of the
normal rupture pressure for tension-loaded disks, and at least 10 % of the minimum
rupture pressure for reverse-buckling disks) shall be allowed between the MOP and
the design pressure of the equipment.
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2.2.1.3.4 Liquid-full systems

1. Liquid-full systems shall be designed to withstand pump shut-off pressure if they can
be “blocked in” while pumps feeding them could continue to operate.
The shut-off pressure is the pressure at the discharge of a centrifugal pump with the
suction pressure at the maximum possible value and the discharge system closed.
The shut-off pressure (SOP) is determined by the equation:
SOP = SP + HPs + HPo - HPd
where:
SP is the set pressure of the pressure relief device on the pump suction system
HPs is the hydrostatic pressure of the liquid above the pump suction
HPo is the pump differential pressure at no flow and maximum pump speed and
highest density as per process design
HPd is the hydrostatic pressure of the liquid above the pump discharge
2. If the shut-off pressure condition and the suction relief condition have a common
cause, the accumulated relief pressure shall be used instead of the set pressure of the
relief device.
3. For systems that do not normally operate liquid full, but could become liquid fill during
a transient or upset condition, an evaluation shall be undertaken to determine whether
the system is to be designed for shut-in pressure or whether some other means of
safeguarding is required.
4. Consequence evaluation of liquid-full systems shall include overpressure, potential
liquid release to relief systems and additional weight of liquid imposed on structural
supports.
5. For steam or gas turbine driven pumps and variable speed electric motor driven
pumps, the maximum possible speed during operation of the pump shall be evaluated
since this can influence the design pressure considerably.
Differences of more than 25% between differential head at normal running speed
and maximum running speed are not unusual.
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2.2.1.3.5 Shell-and-tube heat exchangers

1. The most unfavourable combination of design pressures on the shell and tube side
that occur during transient or failure conditions and blocking in, shall be used in the
calculations for tubesheets, floating heads and tubes.
2. The design pressure of the high pressure side of the exchanger should be lower than
the corrected hydrotest pressure of the low pressure side of the exchanger or, a relief
device is required to protect against tube rupture.
As an example, a 10/13 rule could be required by a local code.
3. If design pressure is specified to eliminate the need for a relief device for tube rupture,
the (mechanical) design pressure of the low pressure side of the exchanger shall be
extended up to and including the block valves.
4. All parts of a heat exchanger that are subjected solely to a differential pressure may,
be designed based on the maximum differential design pressure between shell and
tube side.
a. A warning sign, per standard drawing S21.071, stating the maximum differential
design pressure and the maximum differential test pressure, shall be located next
to the nameplate.
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2.2.1.3.6 Pipeline systems

1.
2.2.1.4 Lower design pressure (LDP)
The LDP is the external design pressure or the sub-atmospheric pressure at the top of
the equipment in its operating position. It is used to determine the minimum thickness of
equipment parts or stiffening rings at the design temperature.
1. With the exception of storage tanks that are protected by pressure-vacuum vents, for
design of process vessels refer to DEP 31.22.00.31-SCAPSA PQ2022.
2. Vessels that are in steam service should be designed for full vacuum at 150 °C
(300 °F).
3. For vapour with an atmospheric dewpoint of 0 °C (32 °F) or above, it shall be checked
whether vacuum can develop in the equipment if the heat input to the equipment fails.
4. If the pressure drop below atmospheric pressure due to utility failure, instrument
failure, low-load conditions, mal-operation, blocked-in situations or any other cause,
the minimum possible absolute pressure shall be stated in the documents for
mechanical design.
5. Steaming-out and draining operations shall be evaluated when determining the LDP.
2.2.1.5 Maximum allowable working pressure (MAWP)
The MAWP is used in the ASME Boiler and Pressure Vessel Code and a number of
other codes referring to it.
The MAWP is the maximum gauge pressure permissible at the top of the equipment with
the equipment installed in its operating position and at a designated temperature.
The MAWP is equal to or greater than the DP.
2.2.1.6 Maximum allowable incidental pressure (MAIP)
MAIP typically refers to pipeline systems as referenced in API RP 1111 and ISO 13623.
Incidental pressure is a term used to describe infrequent short periods of time during
which the pipeline system could be subjected to pressures greater than MAOP.
Examples of incidental pressure include surge, failure of pressure controlling equipment,
and cumulative pressure during activation of overpressure protection devices.
1. The MAIP should not exceed 90% of the hydrotest pressure.
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PART III DEFINITION OF TOXICITY

1 TECHNICAL ASSURANCE
The definition of toxicity is a technical competency that is maintained in the Health
discipline in Shell. As such, the relevant subject matter experts and the custodianship for
(Part III) of this DEP are with the Health discipline. During project development, the
toxicity classification for a substance is specified by the Contractor and then reviewed by
the Principal for technical assurance and subsequent approval.

2 BACKGROUND
This DEP specifies the scheme for defining whether a process medium is deemed to be
very toxic (very toxic – environment, very toxic – acute and/or very toxic – chronic). The
Shell toxicity definitions are given in Table 1. Substances are classified in one or more of
these categories in accordance with (PART III).
Engineering design requirements triggered by these definitions are incorporated into
other DEPs that reference this DEP.
Previous editions of this DEP (prior to December 2008) made reference to "lethal"
service designation. This definition is no longer consistent with the definitions currently
used globally for the classification and labelling of hazardous substances. Internal
definitions have been aligned with those accepted internationally under the Global
Harmonisation System.
In addition, for human health, a distinction has been designated between compounds
with acute and chronic toxicity that may lead to a fatality in the short or longer term,
respectively, enabling more flexibility in specifying specific engineering requirements.
Table 1 Toxicity descriptions

3 TOXICITY CLASSIFICATION OF SUBSTANCES

3.1 GENERAL
Substances classified (according to Part III, Table 1) as very toxic-acute, very toxic-
chronic, and very toxic-environment, are those substances that are very hazardous for
the environment or human health. Process streams that contain very toxic-acute, very
toxic-chronic, or very toxic-environment substances require a specific design to limit
emissions and thereby potential exposure. Table 2 provides examples of substances
that are defined as Very Toxic (according to Part III, Table 1). Streams containing these
substances above the limits specified in the schemes are similarly classified.
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4. The United Nations (UN) Globally Harmonized System of Classification and Labelling
of Chemicals (GHS) shall be used to determine the toxicity classification for a process
medium per (Part III, Table 1). Refer to (Part III, 5).
Table 2 Examples of substances with toxicity classifications per (Part III,
Table 1)
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3.2 TOXICITY CLASSIFICATION OF SUBSTANCES UNDER THE GLOBALLY

HARMONISED SYSTEM OF CLASSIFICATION AND LABELLING (GHS)
3. The flow scheme given in (Part III, 5) shall be used to determine the appropriate
toxicity classification of a process medium under the GHS system.
4. Refer to (Part III, 3.3) for application of the scheme to Petroleum Substances and their
associated streams.
5. Refer to (Part III, Table 2) for an example list of substances used within Shell’s
processes that are defined as very toxic-acute, very toxic-chronic, or very toxic-
ECCN EAR99 DEP 01.00.01.30-SCAPSA
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environment according to the classifications in (Part III, Table 1) under the GHS
scheme.
6. If no information on the process medium is available, the Principal shall be consulted.

3.3 APPLICATION TO PETROLEUM SUBSTANCES

6. Petroleum substance shall be assigned a toxicity classification consistent with (Part III,
Table 1) if they contain the following components:
a. hydrogen sulphide (CAS# 7783-06-4) at >0.1% vol or 0.06% wt; such petroleum
substances shall be classified as "very toxic-acute";
b. benzene (CAS# 71-43-2) at > 5% wt; such petroleum substances shall be
classified as "very toxic-chronic";
c. 1,3-Butadiene (CAS# 106-99-0) at > 1% vol; such petroleum substances shall be
classified as "very toxic-chronic";
d. non-petroleum contaminants present at a concentration that triggers the "Very
Toxic-Acute", "Very Toxic-Chronic", or "Very Toxic-Environment" classification,
according to the selected scheme (Part III, 3.1, Item 1).
7. All other petroleum substance streams shall be defined as “not very toxic", as
described in (Part III, Table 1).

4 SPECIFIED ENGINEERING CONTROLS BASED ON THE SHELL TOXICITY

DEFINITION
1. Where there is no designated design specification, the selection of the engineering
design requirements shall be determined by a Health Risk Assessment.
a. For further guidance on requirements for a Health Risk Assessment, reference
should be made to the latest HSSE&SP Control Framework
2. Risk should be evaluated before determining the degree of equipment needed (i.e.,
double pump seals or double block and bleed).

5 SELECTION OF SHELL TOXICITY DEFINITION UNDER GHS

5.1 GENERAL
A logic diagram for the selection of toxicity definition under the GHS classification system
is shown in Figure 1.
1. Refer to (Part III, 5.2) for an explanation of the process steps.
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Figure 1 Logic diagram – GHS classification system

2. IMPORTANT NOTE REGARDING STEP 3 AND STEP 11

a. Refer to (Part III, Section 3.3) regarding petroleum substances containing
hydrogen sulphide, benzene, 1,3-butadiene, or other non-petroleum
contaminants.
b. Where a substance has been defined as “very toxic acute” on the basis of “skin
corrosion”, there may be over conservativeness in specifying equipment.
c. Risk should be evaluated before determining the degree of equipment needed
(i.e., double pump seals or double block and bleed).
i. Risk Phrases GHS/CLP:
i. H400: Very toxic to aquatic life;
ii. H410: Very toxic to aquatic life with long lasting effects;
iii. H314: Causes severe skin burns and eye damage;
ECCN EAR99 DEP 01.00.01.30-SCAPSA
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iv. H318: Causes serious eye damage;

v. H300: Fatal if swallowed;
vi. H310: Fatal in contact with skin;
vii. H330: Fatal if inhaled;
viii. H340: May cause genetic effects;
ix. H350: May cause cancer;
x. H360: May damage fertility or the unborn child.

5.2 EXPLANATION OF THE PROCESS STEPS ACCORDING TO GHS

Step 1. Does the process medium contain substances classified as Hazardous to the
environment with risk phrases H400: ‘Very toxic to aquatic life’ or H410: ‘Very toxic to
aquatic life with long lasting effects’?
a. If Yes, go to step 2. If No, go to step 3.
Step 2. Is the (sum of) environment endangering substance(s) present at >25% wt?
a. If the substance is present at >25% (weight/weight %) or unknown, then the
answer is Yes, the substance is “Very Toxic – Environment”. Go to step 3.
b. If the substance is present at  25% (weight/weight %), the process medium is
not classified as “Very Toxic – Environment” and the answer is No, also go to
step 3.
Step 3. Does the process medium contain substances classified for (skin) corrosion with
risk phrases H314: ‘Causes severe skin burns and eye damage’?
a. If Yes, go to step 4. If No, go to step 7.
Step 4. Is the substance gaseous?
a. Check the physical condition of the substance under atmospheric pressure. If the
substance is gaseous, the answer is Yes, go to step 5. If the substance is not
gaseous, the answer is No, go to step 6.
Step 5. Is the substance present at > 1% or H2S at > 0.1% vol?
a. See composition of the substance. If the substance is present at > 1%
(volume/volume %), or if H2S is present at > 0.1% (volume/volume %; equivalent
to 1000 ppm mole), or if the composition of the substance is not known, then the
answer is Yes, the process medium is “Very Toxic – Acute”. Go to step 11.
b. If the substance is present at  1% (volume/volume %), or if H2S is present at 
0.1 % (volume/volume %), then the process medium is not classified as “Very
Toxic – Acute” and the answer is No. Go to step 7.
Step 6. Is the substance present at > 5% wt?
a. See composition of the substance. If the substance is present at > 5%
(weight/weight %), or if the composition of the substance is not known, then the
answer is Yes, the process medium is “Very Toxic – Acute”. If the substance is
present at 5% (weight/weight %), the process medium is not classified as “Very
Toxic – Acute” and the answer is No. Go to step 7.
Step 7. Does the process medium contain substances classified as Acutely toxic Cat 1,
with risk phrases H300: ‘Fatal if swallowed’, H310: ‘Fatal in contact with skin’ or H330:
‘Fatal if inhaled’?
a. If one of the substances is classified for acute toxicity in combination with the risk
phrases H300, H310 or H330, then the answer is Yes, go to step 8. If not, the
answer is No. Go to step 11.
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Step 8. Is the substance gaseous?

a. Check the physical condition of the substance under atmospheric pressure. If the
substance is gaseous, the answer is Yes, go to step 9. If the substance is not
gaseous, the answer is No. Go to step 10.
Step 9. Is the substance present at > 1% or H2S at > 0.1% vol?
a. See composition of the substance. If the substance is present at > 1%
(volume/volume %), or if H2S is present at > 0.1 % (volume/volume %; equivalent
to 1000 ppm mole), or if the composition of the substance is not known, then the
answer is Yes, the process medium is “Very Toxic – Acute”. Go to step 11. If the
substance is present at 1 % (volume/volume %), or if H2S is present at 0.1%
(volume/volume %), then the process medium is not classified as “Very Toxic –
Acute” and the answer is No. Go to step 11.
Step 10. Is the substance present at >7% or H2S at >0.06% wt?
a. See the composition of the substance or Section 2 of the product MSDS. If the
substance is present at >7% (weight/weight %), or if H2S is present at >0.06 %
(weight/weight %; equivalent to 600 mg/kg (0.0006 lb/lb)), or unknown, then the
answer is Yes, the process medium is “Very Toxic – Acute”. Go to step 11. If the
substance is present at  7% (weight/weight %), or if H2S is present at  0.06 %
(weight/weight %) then the process medium is not classified as “Very Toxic –
Acute” and the answer is No. Go to step 11.
Step 11. Is the substance Carcinogenic, Mutagenic, or Reprotoxic (CMR) Category 1A or
1B and labelled with H340: May cause genetic effects, H350: May cause cancer or
H360: May damage fertility or the unborn child?
a. If the symbol C, M, or R, Category 1 or 2 is listed in combination with risk phrases
H350: ‘may cause cancer’, H340: ‘may cause genetic defects’, or H360: ‘May
damage fertility or the unborn child ‘, then the answer is Yes, go to step 12*. If
not, the answer is No. Go to step 15.
b. * Petroleum substances classified as Category 1 or 2 Carcinogens due to their
polycyclic aromatic hydrocarbon content are excluded. Petroleum substances
containing hydrogen sulphide, benzene, 1,3-butadiene, or a non-petroleum
contaminant may be considered very toxic depending on the concentrations of
specific substances. See (3.3).
Step 12. Is this substance gaseous?
a. Check the physical condition of the process substance under atmospheric
pressure. If the substance is gaseous, the answer is Yes, go to step 13. If the
substance is not gaseous, the answer is No. Go to step 14.
Step 13. Is the substance present at > 1% vol?
a. See composition of the substance. If the substance is present at > 1%
(volume/volume %), or if the composition of the substance is not known, then the
answer is Yes, the process medium is “Very Toxic – Chronic”. If the substance is
present at  1% (volume/volume %), then the answer is No, the process medium
is not classified as “Very Toxic - Chronic”.
Step 14. Is the substance present at > 5% wt?
a. See composition of the substance or Section 2 of the product MSDS. If the
substance is present at >5% (weight/weight %), or unknown, then the answer is
Yes, the process medium is “Very Toxic – Chronic”. If the substance is present at
5% (weight/weight %), then the answer is No, the process medium is not
classified as “Very Toxic - Chronic”.
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Step 15. Has a component in the process medium been previously classified as “Very
Toxic – Environment” or “Very Toxic – Acute”?
a. If No, the process medium is ‘Not Very Toxic’. If Yes, the previously assigned
classification stands.
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PART IV REFERENCES
In this DEP, reference is made to the following publications:
NOTES: 1. Unless specifically designated by date, the latest edition of each publication shall be used,
together with any amendments/supplements/revisions thereto.
2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell
Wide Web) at http://sww.shell.com/standards/.

SHELL STANDARDS

DEP feedback form DEP 00.00.05.80-SCAPSA

PQ2022.
Preparation of safeguarding memoranda and process safeguarding DEP 01.00.02.12- SCAPSA
flow schemes PQ2022.
Metallic materials - Prevention of brittle fracture in new equipment DEP 30.10.02.31- SCAPSA
PQ2022.
Unfired pressure vessels DEP 31.22.00.31- SCAPSA
PQ2022.

Shell HSSE & SP Control Framework, Design Engineering Manual DEM1

(DEM) 1 – Application of Technical Standards
https://eu001-
sp.shell.com/sites/AAAAA8432/CF/Web/Design_Engineering_Manual
_1_DEM1.aspx

AMERICAN STANDARDS

Pressure-relieving and Depressuring Systems API STD 521

Power piping ASME B31.1
Process piping ASME B31.3
Pipeline transportation systems for liquids and slurries - Includes ASME B31.4
interpretations through May 15, 2012
Gas transmission and distribution piping systems ASME B31.8
ASME Boiler and Pressure Vessel Code, Section VIII, Division 1: ASME/BPVC SEC VIII-1
Rules for construction of pressure vessels
ASME Boiler and Pressure Vessel Code, Section VIII -Division 1 – ASME/BPVC SEC VIII-1
UG-140 Overpressure protection by system design UG-140
ASME Boiler and Pressure Vessel Code, Section VIII – Division 1 – ASME/BPVC SEC VIII-1,
Appendix M - Installation and Operation Appendix M
Design, construction, operation, and maintenance of offshore API RP 1111
hydrocarbon pipelines (limit state design) - Fourth Edition;
Incorporating Errata: May 2011

BRITISH STANDARDS

Specification for unfired fusion welded pressure vessels - BSI PD 5500

AMD: September 2012

CHINESE STANDARDS

Pressure vessels GB 150

Issued by: Standardization Administration of China
ECCN EAR99 DEP 01.00.01.30-SCAPSA
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EUROPEAN STANDARDS

Regulation (EC) No 1272/2008 of the European Parliament and of the EC 1272/2008

Council of 16 December 2008 on classification, labelling and
packaging of substances and mixtures, amending and repealing
Directives 67/548/EEC and 1999/45/EC, and amending Regulation
(EC) No 1907/2006 (Text with EEA relevance)
Issued by: EU/EC - European Union/Commission Legislative
Documents http://eur-lex.europa.eu
Unfired pressure vessels - Part 2: Materials - Incorporates EN 13445-2
Amendment A2: 2012

INTERNATIONAL STANDARDS

Petroleum and natural gas industries - Pipeline transportation systems ISO 13623
- Second Edition
Globally Harmonised System (GHS) of classification and labelling of ST/SG/AC.10/30/Rev.4
chemicals
Issued by: United Nations Economic Commission for Europe
Information Service http://www.unece.org/trans/danger/danger.htm